Welding cast iron to stainless steel?

Old 12-20-04, 12:54 PM
Chris Wilson
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Welding cast iron to stainless steel?

I have put up a photo of a Toyota Supra twin turbo cast iron exhaust manifold on my web site. It shows how Toyota, or whoever makes the manifolds for them, have welded in a flexible stainless steel expansion belows between 2 pairs of 3 cylinders. The manifold casting is definitely cast iron and magnetic, the bellows are definitely stainless and none magnetic. The weld fusion looks to have been an automated process. How is such a fusion done, and more specifically, how, in the amateur workshop with access to a decent TIG machine, can one offs of a similar nature be attempted? I would like to directly weld a flexible stainless steel bellows to a cast iron manifold to mount a wastegate on, which itself is rigidly suppoerted, the bellows being to allow thermal expansion and contraction.

Pic is at http://chriswilson.tv/manifold.jpg

Old 12-20-04, 05:46 PM
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Never seen it done with TIG but I know it can be done with stick welder. It takes a certain preheat and uses NIrod electrodes. Then a postheat and SLOW cooling period to assure it doesn't crack. Last time I saw a procedure like this, the part was buried in lime and wrapped in insulation for many hours. Sorry I don't remember the pre or post heat temps.
Old 12-21-04, 08:15 AM
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You should be able to Gas Weld (Oxygen & Acetylene or MAPP) the 2 together, much cheaper if you don't have a TIG machine.
Old 01-22-05, 08:34 PM
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